Method of making an absorbent article having double side cuffs

ABSTRACT

An absorbent article having both outwardly extending and upwardly extending side cuffs is disclosed. The article has a perimeter defined at least in part by a pair of oppositely disposed ends and oppositely disposed sides that extend substantially between the ends. A pair of side flanges extends from a proximal portion adjacent an absorbent structure to a distal portion proximate one of the article sides. Each side flange has a base element, an outer zone disposed adjacent the perimeter and an inner zone disposed between the outer zone and the absorbent structure. There is an elastically extensible element having a width sufficient to span at least the inner zone and a portion of the outer zone, a thickness, and a length. Each elastically extensible element is laminated to the cover material to form a cuff laminate. Each cuff laminate is attached to the base element of the side flange in the outer zone, but each is unattached to the base layer in the inner zone. Finally, the cover is attached to the absorbent structure, at least in a central region of the article. Thus, at least a portion of each cuff laminate is deflected away from the base element of each side flange proximate the inner zone when the elastically extensible element is in a relaxed state.

This is a Divisional of prior application Ser. No. 09/107,394, filedJun. 30, 1998, now U.S. Pat. No. 6,171,290.

FIELD OF THE INVENTION

The present invention relates to absorbent articles having side cuffs toreduce side leakage, more particularly to absorbent articles having bothoutwardly extending and upwardly extending side cuffs.

BACKGROUND OF THE INVENTION

Developers continually try to improve the fluid containment and comfortof absorbent articles, such as diapers, incontinence guards, andsantionary napkins. They have addressed side leakage problems by theaddition of flexible, often elasticized, outwardly-extending, leg cuffssuch as disclosed in Mesek et al., U.S. Pat. No. 4,388,075, Mesek U.S.Pat. No. 4,938,754, and Menard et al., EP 0 534 488.

Later, product developers added upwardly extending “barrier cuffs” nearthe side edge of the absorbent structure in the absorbent articles.Examples of these barrier cuffs can be seen in Enloe, U.S. Pat. No.4,695,278, Lawson, U.S. Pat. No. 4,695,278, Buell, U.S. Pat. No.4,900,317, and LeMahieu et al., U.S. Pat. No. 5,620,431. These barriercuffs are often added as separate pieces that must be handled andattached to the absorbent article. These cuffs also include individualor multiple elastic strands or ribbons, and they apply the contractingforces in discrete, spaced, regions.

What is needed is a novel absorbent article having both an outwardlyextending side flange and an upwardly extending barrier cuff that iscomfortable to the user and that is easily manufactured in a continuous,commercial manufacturing process.

SUMMARY OF THE INVENTION

An absorbent article having both outwardly extending and upwardlyextending side cuffs is disclosed. The article has a perimeter definedat least in part by a pair of oppositely disposed ends and oppositelydisposed sides that extend substantially between the ends. The articlehas a liquid permeable cover material, a liquid repellent barriermaterial attached to the cover material proximate the perimeter, and anabsorbent structure disposed between the cover material and the barriermaterial. A pair of side flanges extends from a proximal portionadjacent the absorbent structure to a distal portion proximate one ofthe article sides. Each side flange has a base element, an outer zonedisposed adjacent the perimeter and an inner zone disposed between theouter zone and the absorbent structure. There is an elasticallyextensible element having a width sufficient to span at least the innerzone and a portion of the outer zone, a thickness, and a length.

Each element is connected to each side flange, and the length of theelastically extensible element is substantially greater than its width,which in turn is substantially greater than its thickness. Eachelastically extensible element is laminated to the cover material toform a cuff laminate. Each cuff laminate is attached to the base elementof the side flange in the outer zone, but each is unattached to the baselayer in the inner zone. Finally, the cover is attached to the absorbentstructure, at least in a central region of the article. This permits atleast a portion of each cuff laminate to be deflected away from the baseelement of each side flange proximate the inner zone when theelastically extensible element is in a relaxed state. The invention alsorelates to a process for forming such an article.

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 shows a perspective view of an absorbent article according to thepresent invention.

FIG. 2 shows a side elevation of the absorbent article of FIG. 1.

FIG. 3 shows a cross-section along line 3—3 of FIG. 1.

FIGS. 4-6 show partial views of the cross-section of FIG. 3 of threealternative embodiments.

FIG. 7 illustrates a schematic diagram of the method of forming anabsorbent article according to the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring to FIGS. 1-3, an absorbent article 10 having a perimeterdefined at least in part by a pair of oppositely disposed ends 12 andoppositely disposed sides 14 that extend substantially between the ends12.

The article 10 has a body facing surface 16 and a garment facing surface18. The article 10 has a liquid permeable cover 20 and a liquidimpermeable barrier 22.

The cover 20 and the barrier 22 are attached proximate the perimeter ofthe article 10. An absorbent structure 24 is disposed between the cover20 and the barrier 22.

A side flange 26 extends outwardly along each side 14 of the article 10.Each side flange 26 extends outwardly from a proximal portion 28adjacent the absorbent structure 24 to a distal portion 30. Each sideflange 26 has a base element 32, an outer zone 34 disposed adjacent theperimeter of the article 10 and an inner zone 36 disposed between theouter zone 34 and the absorbent structure 24.

An elastically extensible element 38 is operatively connected to eachside flange 26. The elastically extensible element 38 is formed into acuff laminate 39 with the cover 20, at least proximate the sides 14.Preferably, a first surface 40 of the elastically extensible element 38is laminated to the cover 20 to form this cuff laminate 39. The cufflaminate 39 is attached to the base element 32 in the outer zone 34, butit is not directly attached to the base element 32 in the inner zone 36.Preferably, a second surface 42, opposite the first surface 40, formsthe exposed portion of the cuff laminate 39 that is attached to the baseelement 32 in the outer zone 34. Therefore, at least a portion of thecuff laminate 39 is deflected away from the base element 32 of each sideflange 26 proximate the inner zone 36 to form an upwardly extendingbarrier cuff 44.

The cover 20 is a liquid permeable element, and it is useful to containthe absorbent structure 24, permit bodily exudates to pass into theabsorbent structure 24, at least partially to mask absorbed bodilyexudates, and to provide a comfortable body facing surface 16. The cover20 may be of any structure that is sufficiently flexible to flex withthe absorbent article 10 and that is capable of allowing bodily fluidsto pass therethrough while substantially containing any potentiallymobile components of the absorbent structure 24. A representative,non-limiting list of useful structures includes woven fabrics, nonwovenfabrics, apertured or perforated films, porous foams (includingperforated foams), sintered plastics, and the like. A representative,non-limiting list of materials useful in forming such structuresincludes cellulosics, such as cotton, rayon, wood fluff pulp, and thelike; hydrocarbon synthetics, such as polyolefins, polyesters,polyurethanes, polyamides, polytetrafluoroethylene (“PTFE”), and thelike; silicones, such as polysiloxanes and the like; bonding agents;wetting agents, such as surfactants; and any other materials which areuseful as absorbent article components. One or more of these materialsmay be included in a laminated structure to form the cover 20.

Preferably, the cover 20 is formed from a sheet of flexible materialthat has a basis weight of less than about 60g/m² (“gsm”), a morepreferred basis weight is between about 10 and about 60 gsm, and a mostpreferred basis weight is between about 15 and about 35 gsm.

The barrier 22 is a preferably a liquid impermeable element, and it isuseful to contain the absorbent structure 24, prevent bodily exudatesfrom passing out of the absorbent structure 24 to the user's garments orotherwise, and to provide a comfortable garment facing surface 18. Thebarrier 22 may be of any structure that is sufficiently flexible to flexwith the absorbent article 10 and that is capable of preventing bodilyfluids from passing therethrough and also substantially containing anypotentially mobile components of the absorbent structure 24. Arepresentative, non-limiting list of useful structures includes fabrics,such as nonwoven and woven fabrics; films, including apertured,perforated, or microporous films; foams, such as porous or nonporous,closed cell foams; sintered plastics, and the like. A representative,non-limiting list of materials useful in forming such structuresincludes cellulosics, such as cotton, rayon, wood fluff pulp (includingpaper and coated or otherwise laminated paper), and the like;hydrocarbon synthetics, such as polyolefins, polyesters, polyurethanes,polyamides, PTFE, and the like; silicones, such as polysiloxanes and thelike; bonding agents, repellents, and other material treatments; and anyother materials which are useful as absorbent article components. One ormore of these materials may be included in a laminated structure to formthe barrier 22.

Preferably, the barrier 22 is formed from a sheet of flexible materialthat has a thickness of less than about 2 mm. More preferably thebarrier is formed from a film having a thickness of less than about 0.1mm, and most preferably between about 0.01 and about 0.05 mm.

The absorbent structure 24 is used to acquire and to retain exudedbodily fluids. The absorbent structure 24 may be a single, substantiallyuniform structure, or it may be a more complex, layered or otherwiseasymmetrical structure. In a preferred embodiment, the absorbentstructure 24 comprises at least one intermediate layer 46 and at leastone retention element 48. The intermediate layer(s) 46 may be arrangedand configured to acquire, distribute, temporarily hold, and/or maskbodily exudates and to help to stabilize the whole absorbent structure24, while the retention element will generally take up such bodilyexudates from the intermediate layer(s). In a particularly preferredembodiment as shown in FIG. 3, a first intermediate layer is disposedbetween the retention element 48 and the cover 20, is wider than theretention element 48, and extends at least into the inner zone 36 of theside flange 26. Again, this helps to stabilize the retention element 48.In another embodiment shown in FIG. 4, the absorbent structure 24′ is asingle layer. In yet another embodiment shown in FIG. 5, an intermediatelayer 46″ is disposed between the retention element 48″ and the barrier22″. This intermediate layer 46″ may be used as a wicking layer orstabilizing element.

The absorbent structure 24 and/or the individual layers (intermediatelayer(s) 46 and/or retention element 48) may be of any structure that issufficiently absorbent of bodily fluids to function as a sanitarynapkin, incontinence device, diaper, or similar product. Arepresentative, non-limiting list of useful structures includes wovenfabrics, nonwoven fabrics (including fibrous batts, tissues, and thelike), apertured or perforated films, porous foams, sintered plastics,and the like. Such structures may also include conventional absorbentmaterials and high absorbency materials such as superabsorbent foams,particles, fibers, films, sheets, and the like. A representative,non-limiting list of materials useful in forming such structuresincludes cellulosics, such as cotton, rayon, wood fluff pulp, sphagnum,and the like; hydrocarbon synthetics, such as polyolefins, polyesters,polyurethanes, polyamides, PTFE, and the like; superabsorbent materials,such as hydrolyzed, cross-linked polyacrylates, polyacrylonitriles,acrylics, grafted polymers, and the like; odor-control agents, such asfragrances, zeolites, sequesterants, and the like, and any othermaterials which may be useful as absorbent article components.

The length of the elastically extensible element 38 is substantiallygreater than its width, and the width is substantially greater than thethickness of the extensible element 38. The elastically extensibleelement 38 may be of any elastically extensible structure that iselastic to impart a raised cuff and longitudinal curve to the article10. A representative, non-limiting list of useful structures includessheets, films, foams, ribbons, woven or nonwoven webs, and the like. Arepresentative, non-limiting list of materials useful in forming suchstructures includes hydrocarbon synthetics, such as polyolefins,polyesters, polyurethanes, polyamides, PTFE, block copolymers (such asstyrene-butadiene-styrene and styrene-isoprenestyrene copolymers),ethylene-vinyl acetate copolymers, synthetic rubber, and the like;silicones, such as polysiloxanes and the like; natural rubber; and anyother materials which are useful as absorbent article components.

The properties of the elastically extensible element 38 are balancedwith the properties of the rest of the materials used to fabricate theabsorbent article 10. This allows the elastically extensible element 38to curve the article 10 in the longitudinal direction, and to formbarrier cuffs 44 along the article's side edges 14. Preferably, theelastically extensible element 38 is formed from a sheet of elastomericmaterial having a tensile strength of less than 200 psi, morepreferably, from about 10 to 100 psi, and most preferably, from about 25to about 50 psi. Additionally, it is preferred that the elastomericmaterial has an elongation to break of at least about 100%, morepreferably, from about 200% to about 350%, and most preferably, fromabout 250% to about 300%. These materials can be tested according toASTM D-3574-95. It is also preferred that the recovery of the materialbe at least about 60%, more preferably, at least about 80%, and mostpreferably, at least about 90%.

While we do not wish to be held to this theory, it is believed that asheet of elastomeric material or a similar geometry has uniqueproperties that allow the present invention to be achieved. First, uponelongation under tension, both the thickness and width of the materialdecrease. When portions of the material are then secured in thetensioned condition and the tension is subsequently released, it isbelieved that the material will attempt to regain at least some of bothits thickness and its width. Thus, the material buckles and separatesfrom the base element 32 to form the upstanding barrier cuff 44. Inorder to optimize this, the width of the elastically extensible element38, the inner zone 36 and the outer zone 34 are balanced to provide theupstanding barrier cuff 44. If there is insufficient width to the innerzone 36, there will be very little if any barrier cuff 44. Conversely,if there is insufficient width in the outer zone 34, the side cuff willbe substantially eliminated.

As discussed above, a cuff laminate 39 is formed comprising the firstsurface 40 of the elastically extensible element 38 and the cover 20.The elastically extensible element 38 is preferably combined in thiscuff laminate 39 in an extended state. The cuff laminate 39 is attachedto the base element 32 in the outer zone 34 of the side flange 26, butit is not directly attached to the base element 32 in the inner zone 36.Thus, the cuff laminate is able to separate from the base element 32inwards of the outer zone 34 to form the upwardly extending barrier cuff44 as the elastically extensible element 38 reverts to a relaxed state.

The material used for the base element 32 may be the similar to thematerial used for the cover 20 and/or the barrier 22, as describedabove. The base element 32 itself may be a separately attached element,but it is preferred that the base element 32 is a continuation of thebarrier 22 as shown in FIG. 3. In this embodiment, it can be seen thatthe side flange 26 is formed of the materials of construction of therest of the absorbent article 10, and no additional structure need bemanipulated and attached to the product to form both the outwardlyextending side flange 26 and the upwardly extending barrier cuff 44.

Of course, if the base element 32′″ is formed of a separate element,this separate element could be attached to the rest of the absorbentarticle 10 as shown in FIG. 6. In this embodiment, both the cover 20′″and the elastically extensible element 38′″ extend only to the side edge14′″ of the article 10′″. The attachment may be adhesive, ultrasonic,sewn, or other attachment mechanisms that will be known to those ofordinary skill in the art.

The separation of the cuff laminate 39 and the base element 32 in theinner zone 36 may be achieved by several methods. If the two elementsare adhesively attached, the separation may be achieved by: (1)preventing the application of adhesive material between the elements inthe inner zone 36; (2) detackifying any adhesive material present in theinner zone 36; (3) masking such adhesive; or (4) other methods asrecognized by those skilled in the art. If the elements are attachedthrough heat and/or pressure, the separation may be achieved by: (1)maintaining the inner zone at a temperature and/or pressure below thatnecessary for bonding; (2) maintaining a separation between the elementsin the inner zone 36 during the attachment of the elements; or (3) othermethods recognized by those skilled in the art. Further attachmentmethods and related separation methods will also be recognized by thoseskilled in the art.

The absorbent article 10 may be made by hand, or it may be manufacturedaccording to a process such as is outlined in FIG. 7 and describedbelow. First, the cover material 100, is unwound from a supply roll. Afirst laminating adhesive material 102 is applied to a surface of thecover material 100, and elastically extensible material 104 is stretchedand adhered to the cover material 100. This forms a cuff laminate in oneor more regions of the cover material 100. Preferably, the elasticallyextensible material 104 is stretched at least about 10% prior to beingadhered to the cover material. More preferably, it is stretched fromabout 10% to about 40%, and most preferably, it is stretched from about15% to about 30%.

An intermediate layer 106 may then be adhered to the cover material 100in a manner to overlap the elastically extensible material 104. It isthis overlap that can prevent the later lamination of the cuff laminateand the base element. After the intermediate layer 106 has been adheredto the cover material 100, a second adhesive material 108 can be appliedto the construction. This second adhesive material 108 may cover atleast a portion of the intermediate layer 106. A retention element 110can then be placed on the construction and adhered to the intermediatelayer 106.

Finally, a barrier material 112 is applied to the construction. Thebarrier material 112 is preferably narrower than the cover material 100to allow the extreme edges of the cuff laminate to be wrapped around theside edges 114 of the barrier material 112 and secured on the exposedsurface of the barrier material 112, e.g., at a folding station 118. Thebarrier material 112 may have disposed thereon a construction adhesive116. Individual absorbent articles 120 may be formed from the resultingconstruction proximate the longitudinal ends of the absorbent structure110, e.g., with a reciprocating cutter 122 or a rotary cutter (notshown). Attachment adhesive protected by a release liner may then beapplied to a portion of the remaining exposed regions of the barriermaterial 112. The resulting products can then be packaged and storeduntil use.

In an alternative embodiment in which the intermediate layer ispositioned between the retention element 110 and the barrier material112, the process may be modified slightly. The retention element 110would be placed onto the second adhesive material 108 between theelastically extensible (may overlap slightly the elastic) material 104.Laminating adhesive 116 again may be applied on the barrier material112. An intermediate layer, wider than the retention element, would beapplied to the barrier. Another layer of laminating adhesive can beapplied in the middle of this intermediate layer to insure good bondingof the retention element. This construction is then joined to thecover/elastic/retention layer. The portion of the intermediate layerthat is wider than the retention element deactivate the adhesive therebycreating the raised region 44.

In a second alternative method of fabrication in which the intermediatelayer is eliminated, the process would again be modified. In particular,the retention element 110 is placed on the second adhesive material 108between the elastically extensible (may overlap slightly the elastic)material 104. However, this second adhesive material 108 is applied suchthat there are two regions without applied adhesive on both sides of theretention element 110. The process continues as described above with theapplication of the barrier material 112 to the retention element 110 andcover/elastic construction. Again, the barrier material 112 should befree of adhesive in a region that corresponds to the uncoated portion ofthe cover. These uncoated portions of the cover material 100 and barriermaterial 112 prevent the attachment of these elements in the inner zoneto create the barrier cuff 44.

In use, the product may be removed from its packaging, and, e.g.,attached in the crotch portion of a user's undergarment after theattachment adhesive is exposed. When so attached, the elasticallyextensible element 38 can relax to impart a curve along the longitudinalaxis of the product, and to urge the cuff laminate 39 away from the baseelement 32 to form upwardly extending barrier cuffs 44 to help toprevent bodily exudates from leaking around the longitudinal sides 14 ofthe article 10.

The specification and examples above are presented to aid in thecomplete and non-limiting understanding of the invention disclosedherein. Since many variations and embodiments of the invention can bemade without departing from its spirit and scope, the invention residesin the claims hereinafter appended.

What is claimed is:
 1. A method of forming an absorbent articlecomprising the steps of: a) elongating a first elastically extensiblematerial and attaching it to a substantially continuous length of acover material to form a first cuff laminate proximate a first sidemargin of the cover material; b) attaching a discrete length of anabsorbent structure having longitudinal ends and lateral sides adjacentthe elastically extensible material, leaving the elastically extensiblematerial substantially uncovered by the absorbent structure; c)attaching a substantially continuous length of a barrier material to theabsorbent structure, to a portion of the cover material adjacent thelongitudinal ends of the absorbent structure, and to a portion of thecuff laminate proximate the side margin of the cover material, leaving aportion of the cuff laminate in an inner zone, between the side marginof the cuff material and a side margin of the absorbent structure,substantially unattached to the barrier material; and d) separating anabsorbent article from the continuous length of the cover material. 2.The method of claim 1 further comprising the step of elongating a secondelastically extensible material and attaching it to the substantiallycontinuous length of the cover material to form a second cuff laminateproximate a second side margin, opposite the first, of the covermaterial.
 3. The method of claim 2 further comprising the step ofattaching an intermediate layer to the cover material between the firstand second elastically extensible materials.
 4. The method of claim 1further comprising the step of attaching an intermediate layer to thebarrier material.
 5. The method of claim 1 further comprising the stepof applying an adhesive material to the cover material, the first andsecond elastically extensible materials, and the barrier material in atleast one pattern to avoid attachment of all of the cover material, atleast one of the elastically extensible materials and the barriermaterial in the inner zone.